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Shampoo filling Equipment

Filling lines are used extensively in all industries, such as food, pharmaceutical, chemical, and cosmetics, to accurately package different products into a container suitable for that product. Although the filling process is at the very end of the production line, it is no less important than the earlier steps. Last but not least, the idiom that dates back to 1382 when John Wyclif wrote the firste the laste, and the laste the firste, indicates just that the last things on a list are just as valuable as the previous ones. In this case, this idiom fits perfectly.

Filling

Shampoo is a unique form of cleaning agent composed primarily of water and some form of surfactant. This surfactant provides the ability to bind oily substances for removal without leaving a residue, as traditional soaps might. The production process involves the batch mixing of its laboratory-defined formula, quality control, and filling stages.

Shampoo

In terms of high-frequency technology, the fill level detection is considered a standard method nowadays. It inspects glasses and PET bottles of almost any shape and colour, in particular for liquids with little or no foam.


<h2>Inspect the filling level for liquids with little or no foam</h2>
The Newton HF from Miho greatly improves the HF measurement process. Without carrying out any special precautionary measures, the HF technology is very sensitive towards changes in temperature that lead to measuring drifts and eventually to changes in the fill levels measured. Miho Newton HF resolves these problems because it is a machine that permanently controls and calibrates itself.

Miho Newton High-frequency fill level controller represents a level of accuracy and reliability that has not been known up until now thanks to the HF fill level control. With this machine the HF inspection process has certainly reached new heights.

High-frequency fill level controller

For containers that are difficult to see through, such as cans or cartons lined with aluminium, an X-ray inspection can be a good solution when looking for fill level control.


<h2>Fill level inspection for cans, cartons lined with aluminium and foiled containers and bottles</h2>
The Newton X2p from Miho is an X-ray fill level inspection unit that inspects cans, cartons lined with aluminium and foiled containers and bottles. The X-ray fill level controller distinguishes itself by requiring less than a tenth of the average amount usually used during the radioactive inspection for its measurement process.

Its core piece is an X-ray generator, which in contrast to traditional X-ray fill level inspection units only generates X-rays for a short moment during the measurement. The total radiation intensity is, therefore, only a fraction of what is the case with traditional X-ray fill level inspection units. The exact value depends upon the number of containers inspected.

X-ray fill level controller

High-speed, high precision X-ray system to inspect containers that are difficult to see through, such as cans or cartons lined with aluminium.


<h2>State of the art fill level inspection for foiled containers and bottles</h2>
The Newton X2Z from Miho is an X-ray fill level inspection unit that inspects foiled containers and bottles. It distinguishes itself by requiring less than a tenth of the average amount usually used for inspection by radiation for its measurement process. And thus the amount of radiation exposure is also reduced. This reduction is due to X-ray technology developed for this purpose by Miho inspection system.

The core piece of the High-precision X-ray fill level controller  is an X-ray generator, which in contrast to traditional X-ray fill level inspection units only generates X-rays for a short moment during the measuring process. The total radiation intensity is therefore only a fraction of what is the case with traditional X-ray fill level inspection units. The exact value depends upon the number of containers inspected.

High-precision X-ray fill level controller

<span style="font-weight: 400;">Filling and capping bottles and pots for food, chemical and cosmetics industries using separate machines is expensive and inefficient.A better solution is a combined monoblock unit, that will save space and cost, whilst increasing product throughput, even on multi-product lines.</span>
<h3><b>Monoblock combined filling and sealing machine</b></h3>
<span style="font-weight: 400;">EFM Monoblock filling machine is an easy-to-use, multi-purpose machine designed for filling and capping of containers with lids or pressure caps. Featuring a touchscreen system, the machine is easy to operate and allows simple readout and storage of all function information.</span>

<span style="font-weight: 400;">EFM’s design philosophy is to provide adaptable machines suitable for a range of industries. The Monoblock filling machine can be used with a wide variety of filling methods, including digital flow metering, piston pumps, peristaltic pumps, and more.</span>

<span style="font-weight: 400;">For the sealing process, a choice of methods is available including manual positioning of lids, or use of a fully automated cap supply system that uses pick and place. Final tightening can be by magnetic capping, servo capping, pressure capping or pilfer proof capping, to suit your requirements.</span>

Compact monoblock filler

<span style="font-weight: 400;">For larger production runs of food, non-food and cosmetics industries, where accuracy and volume of filling is required, a fully-automated vessel filling solution that works seamlessly with your line is vital. Ease of operation and precision control over fill volume of a large spectrum of liquids provides maximum flexibility for multi-product environments.</span>


<h3>Flexible high-volume flowmeter solution</h3>
<span style="font-weight: 400;">The EFM F-Series is a fully customisable, high accuracy, high volume filling machine. Capable of operating with a wide spectrum of liquids, the F-Series is available in 2,4,6, or 8 head versions. The high efficiency supply pump transfers product directly to the flow meter, where it’s then sent in compressed tubes to the fill valves, which are servo-controlled for accuracy of placement.</span>

<span style="font-weight: 400;">Fitted with electromagnetic flow meters by default, the EFM F-Series can also be supplied with mass flow meters for use with non-water-based product. It can also be fitted with conductivity measurement where required.</span>

<span style="font-weight: 400;">The F-Series is made primarily of stainless steel, and it’s designed to be easily and quickly disassembled for cleaning.</span>

Flowmeter filler

<span style="font-weight: 400;">In many food, chemicals and cosmetic industry processes it is vital to have a quick, accurate and reliable filling and sealing solution that can handle a wide variety of liquid types, including high viscosity and foaming products, into a range of bottle types.</span>


<h2><b>High capacity filler and capper capable of handling wide range of product</b></h2>
<span style="font-weight: 400;">The EFM Inline Monoblock Linear Filling and Capping series is available in both flowmeter and servo piston configurations to suit your exact requirements. Able to operate at up to 2,600 bottles per hour and fill volumes up to 30,000ml depending on model configuration, the Inline Monoblock is constructed in the Netherlands using all stainless steel and standardised components for longevity and ease of maintenance. Remote support from EFM engineers is also available for full peace of mind.</span>

<span style="font-weight: 400;">All variants features Siemens PLC and touchscreen controls, and all product contact points are of 316 stainless steel construction for longer life even when used with corrosive product. A polycarbonate safety casing gives superior protection and allows for excellent visibility for monitoring the filling and capping cycle. The capping module features high-torque sealing and a self-contained Detect and Reject operation to confirm the integrity of the seal, ensuring product quality.</span>

<span style="font-weight: 400;">The flowmeter variants are fitted with Endress &amp; Hauser Mag or Mass flowmeters, and both flowmeter and servo piston versions feature bottle counting, individual centering detection and automated filling bridge height adjustment.</span>

In-line monoblock linear filler &amp; capper

<span style="font-weight: 400;">For the stand-alone capping of bottles of up to 2.5litre capacity you need a robust and flexible machine with high speed and accuracy. Used in the beverage and chemicals industries, bottle cappers need to be reliable and fast, and for maximum flexibility need to be able to deal with a range of caps.</span>


<h2><b>Fully automated standalone capper for bottles up to 2.5 litre</b></h2>
<span style="font-weight: 400;">The EFM range of Multi-Head Capping machines offer maximum flexibility together with impressive performance. These all-stainless machines feature Siemens PLC and full touchscreen controls for accuracy and ease of use. The use of standardised components throughout from high-quality manufacturers increases longevity and reduces the downtime for any maintenance. The gravity-fed cap sorter and magnetic torque head provide high levels of reliability.</span>

<span style="font-weight: 400;">Able to handle a wide range of caps types, including screw caps, push ons, non-vacuum twist-offs and pilfer proof, the EFM multi-head range includes variants able to operate from 4,000 bottles per hour up to 9,000 bottles per hour with the 8 head unit.</span>

<span style="font-weight: 400;">Flexible options include screw infeed, second cap sorter for extremely quick changeovers, torque verification and Detect and Reject system for full capping verification. The units are also available with an optional remote support package direct from the manufacturer.</span>

Multi-head capper

<span style="font-weight: 400;">For food and non-food liquid products that are high foam or have a high viscosity a specialist filling solution is required. Whether filling jars, cans, bottles, top-downs or bowls, the filling machine needs to offer high levels of accuracy and reliability whilst being able to operate at high volumes.</span>


<h2><b>Servo-controlled piston filling machine for high viscosity liquids</b></h2>
<span style="font-weight: 400;">The EFM Servo Piston range of filling machines has been designed specifically for use with high viscosity and high foam liquids in the food, chemical and cosmetics sectors. Featuring robust all-stainless construction and high quality Siemens PLC and touchscreen control, the Servo Piston variants offer accurate and reliable fills at up to 5,200 bottle per hour.</span>

<span style="font-weight: 400;">Featuring standardised components for ease of maintenance and minimal downtime, the EFM servo piston machines are designed to handle volume ranges from 15cc up to 1,100cc depending on configuration.</span>

<span style="font-weight: 400;">For speciality products there are a wide range of options and upgrades available, including heated product tank, product agitators and nitrogen injection.</span>

<span style="font-weight: 400;">Constructed in the Netherlands, EFM also offers an optional remote support service for complete peace of mind.</span>

Servo controlled filler

<span style="font-weight: 400;">For the stand-alone capping of bottles of up to 30 litre capacity for smaller-scale production you need a robust and flexible machine with high accuracy. Used in the beverage and chemicals industries, bottle cappers need to be reliable and fast, and for maximum flexibility need to be able to deal with a range of caps.</span>


<h2><b>Flexible single-head capping machine for smaller-scale production lines</b></h2>
<span style="font-weight: 400;">The EFM range of single head capping machines offer maximum flexibility together with impressive performance for smaller scale production lines. These all-stainless machines feature Siemens PLC and full touchscreen controls for accuracy and ease of use. The use of standardised components throughout from high-quality manufacturers increases longevity and reduces the downtime for any maintenance. The gravity-fed cap sorter and magnetic torque head provide high levels of reliability.</span>

<span style="font-weight: 400;">Able to handle a wide range of caps types, including screw caps, push ons, non-vacuum twist-offs and pilfer proof, the EFM single-head range includes a standard edition able to cap up to 2,200 bottles per hour, and a servo-controlled edition capable of up to 2,600 bottles per hour.</span>

<span style="font-weight: 400;">Featuring a star wheel positioner as standard, the machine is able to fill bottle of up to 2.5 litres. However, by specifying the option using gates larger packages from 5 up to 30 litres can be filled by this machine, providing great flexibility.</span>

<span style="font-weight: 400;">Other options include high torque sealing, torque verification and Detect and Reject system for full capping verification. The units are also available with an optional remote support package direct from the manufacturer.</span>

Single head capper

From thin liquid baby oils and perfumes to thicker lotions and creams for hair and skincare, cosmetic products include a wide range of goods. In an industry where there are a plethora of product types, it’s essential to use a filling machine that can be adapted to the different consistencies of lotions and creams.
<h2>Automatically fills and closes jars, glasses, and tins for cream</h2>
Engineered by Wick Machinery, the DFB-T delivers an output of 400 containers per minute and has a filling range of 1 to 300 ml. The in-feed of jars or empty containers can be done manually, by a disc sorting machine, and by a rotary table. All containers are air-cleaned, while various filling systems enable product-specific filling.

The model also features jar coding, film die and foil cutters for precise filling. It also features a sealing station for hot sealing of foil on glass and plastic containers. Lastly, its filling nozzles are specifically designed for individual products, making the DFB-T ideal for tins, glasses, and jars.

Cosmetic cream filler

Spillage and overfilling are common problems in most production lines for bottled products. A good solution to minimize such waste is to have a single system that can both fill the precise amount of liquid to the containers until the desired net weight is reached, as well as perform the capping of the bottled product.
<h2>Filling and capping bottled containers with load cells for net-weight filling</h2>
The Rotary Monobloc from Rejves machinery is a compact two-in-one system that can perform both filling and capping of bottles through rotary mechanisms. This system can be equipped with various filling technologies available for a precise filling process such as net weight, flow meter, level filling, and vacuum filling. This makes the system suitable for most industries and applications, including food and cosmetic products. A notable feature to reduce cap waste is a bottle detection system that prevents the capping section from supplying caps if no bottle is detected. An optional feature provides a rinsing section using water or ionized air. Production capacity for this system can go as high as 620 bottles per minute.

Bottle filling and capping monobloc

If you have separate filling and capping stations you may experience lower throughput rates due to increased operating cycle time. In addition, if the production line handles multiple products such as liquids, oils, creams, and pastes, changing products and containers between two filling batches can take a significant amount of time.


<h2>Fill and cap up to 35 containers per minute using a monobloc system</h2>
The Response Monobloc Filler &amp; Capper from The Adelphi is a two-in-one system that achieves the dual functionality of filling and capping containers. This versatile unit can be effectively used to fill bottles, jars, and screw-top vials with a variety of products such as oils, creams, serums, scrubs, sauces, peanut butter, or honey. The ‘No container, no fill’ sensor reduces waste of both container and product. Precise torque application gives a higher quality of capping reducing rejects and consecutively the operator’s time to handle rejected containers.

The unit can fill volumes of 5ml to 250ml, with a fill accuracy of up to ±0.25% (superior to the industry average of ±1%). Its fast filling and capping ability can give productive output at up to 35 containers per minute. The system accuracy is complemented by an enhanced quality control process where it can pre-set the quality-check count.

Monobloc filler and capper

In the personal care industry, ensuring consistent filling and capping of products such as liquid soaps, skin and sun care lotions, and hair care solutions is essential. Operators require a seamless process to handle different bottle shapes and cap dimensions efficiently.
<h2>Optimizes filling and capping of personal care products</h2>
The LRF - PC from ACMA (Coesia Group) is a continuous motion rotary filler capper, designed specifically for personal care products. This equipment accommodates various production speeds and is adaptable to different bottle and cap sizes and shapes. Its continuous motion further enhances its capability for high efficiency and minimal downtime. With precision engineering, it ensures accurate filling levels and secure capping, crucial in maintaining the quality and presentation of the final product. The LRF - PC is ideal for liquid soaps, skin and sun care, and hair care products. The versatility and robust design make it suitable for a diverse range of personal care applications.

Rotary filler capper for personal care products

In the production of daily chemical products such as detergents and shampoos, it is vital to maintain precision and consistency during the filling process. Without a reliable filling system, companies may face challenges such as spillage, underfilling, and contamination, leading to costly waste and faulty products.
<h2>Ensuring precise and efficient liquid filling</h2>
The Automatic Daily Chemical Detergent Shampoo Filling System by Alps Machine is a high-tech solution designed for a variety of liquid viscosities. This system utilizes volumetric and piston filling techniques to achieve precise filling volumes from 100ml to 2L, handling capacities between 1000 to 5000 liters per hour. The filling system incorporates a servo motor drive and SUS316L material for the piston to ensure speed and stability. Each filling head is equipped with an air cylinder to provide an anti-leakage function, while the diving system prevents foaming. Users can easily adjust different volume settings to match specific production requirements. Ideal for applications ranging from cleaning liquids to viscous products like tomato sauce and vegetable oil, this filling system ensures high precision with a filling accuracy of +/- 0.5%.

Automatic detergent shampoo filling solution

In high-volume production environments for cosmetics, pharmaceuticals, and food products, precise filling and secure capping of bottles and jars are essential. Managing these tasks manually can result in inconsistency, slower production rates, and increased labor costs.
<h2>Automate filling and capping processes</h2>
The automatic bottles and jars filling and capping line from Axomatic, part of the Marchesini Group, provides a comprehensive solution for filling and capping stable bottles and jars up to 1200 pieces per hour. This system includes a filling module that handles volumes between 50 and 1000 ml with a diving nozzle and anti-drop mechanism to ensure accuracy and cleanliness. The capping section accommodates screw caps, beak caps, or canula nozzles, secured efficiently. A conveyor belt moves products seamlessly from filling to capping, and an outfeed belt with a rotating collection table handles finished products. This integration reduces the need for manual intervention, cuts production time, and ensures product consistency and hygiene.

Automatic bottles and jars filling and capping line

Producing pharmaceutical, cosmetic, or other liquid products often requires precise filling and secure closing of plastic bottles. Ensuring an effective and accurate method for this process is crucial, especially when dealing with large-scale production where quality and consistency are paramount.
<h2>Automatically sort, fill, and close plastic bottles</h2>
The FVK 50400 is an intermittent motion system by Bausch+Ströbel, designed for fully automatic sorting, filling, and closing of plastic bottles. This system employs a walking beam to gently transport the containers through the work area. It features a dosing station outfitted with four rotary piston pumps, ensuring precise liquid filling. Alternatively, the machine can be equipped with peristaltic pumps. The closing stations can handle droppers, screw caps, snap-on caps, and multi-dose dispensers. This machine offers 100% In-Process Control (IPC) at full capacity and processes up to 10,000 items per hour. Container diameters range from 14.25 to 30 mm, and heights from 30 to 67 mm. The product-carrying parts are sterilizable and autoclavable, maintaining optimal laminar air flow, thus satisfying stringent pharmaceutical standards.

Filling and closing solution for plastic bottles

In manufacturing environments, precise liquid filling is essential for maintaining product consistency and quality. Production lines often face issues with accuracy and reliability, especially when handling varying viscosities and fill volumes.
<h2>Automates accurate liquid filling of various viscosities</h2>
The Filltronic by IMA is a positive displacement gear pump liquid filler, widely used since 1981 for its accuracy and reliability. The system employs sanitary stainless steel precision gear pumps that meter the liquid product into containers through positive shutoff nozzles. With a flexible configuration of 2 to 12 pumps, the Filltronic can reach filling speeds of up to 140 bottles per minute, maintaining an accuracy of +/- 0.5%. It is compatible with a wide range of fill volumes from 0.5 ounces to gallons without the need for change parts. This reduces downtime typically associated with piston fillers. The system features motors with integral precision encoders for individual pump control, ensuring continuous operation even if one motor fails. The Filltronic is equipped with instant recall memories for product setups, providing tool-less adjustments and quick-clean pump and nozzle designs. The control system includes an Omron Sysmac PLC and an 8-inch CTC color touchscreen. This technology is particularly suited for the personal and home care industries.

Positive displacement gear pump liquid filler

Rejves Machinery Srl specializes in filling and capping solutions for various sectors, including food, pharmaceutical, home &amp; personal care, as well as industrial &amp; chemical industries. The company produces patented and tailored solutions that can come in different configurations (linear, rotary, or monoblock).

Spilled shampoo can be an issue – not only when you accidentally drop it on your carpet or when it opens in your suitcase. In the <a href="https://making.com/shampoo">process of making shampoo</a>, the filling part needs to be carried out very precisely as to put all resources to use and don’t generate any undesired waste.


<h2>Bubbles and foam: only good in the shower</h2>
Depending on their ingredients, shampoos and conditioners can have foaming properties. This means that they can either form foam and bubbles or splash out of the container during the filling step of the process. In doing so, they dirty the equipment and the container, wasting it and the shampoo it should contain. They also delay the labeling process, which cannot have contaminated containers. In essence, there are more residues, more delays in the process and more economic losses as you will need to replace what was rejected.
<h2>Taking one step back before going two steps further</h2>
Rejves helps cosmetic producers to fill containers accurately at high speeds (up to 620 bottles per minute) using a two-stage nozzle technology. In the first stage, after making sure the bottle is placed where it should be, their rotary Monobloc slowly includes enough liquid to create a thin layer in the bottom of the container. Then, the second-stage nozzle speeds up the process and fills the bottle almost entirely. It starts from the thin layer and goes up, avoiding foam, bubbles and splashing. Finally, the nozzle goes back to the first stage and carefully fills the bottle until the right level. The Monoblock can have more or fewer heads, depending on the products’ characteristics and the desired filling speed. “We can add a mesh to the nozzle or redesign them as well”, says Mirko Nosari, head of Sales and Marketing at Rejves.

Get in touch if you would like to know more and connect with Mirko!

https://www.youtube.com/watch?v=9PERs_-bZ0s

Spill less shampoo when filling your bottles

According to a legend, Cleopatra soaked her sails in her perfume so that Mark Antony could smell her ships before they arrived. This is to say that, from soaps and shampoos to perfumes, conditioners and pomades, cosmetics have always been highly valued and used for their properties of aesthetic enhancement. Cosmetics are a broad class of topical agents applied for various purposes such as cleansing, protecting, beautifying, or otherwise altering your appearance. As a result, a wide array of processing equipment is used in the cosmetics industry.

Cosmetics

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